A Bermondsey-based printing and cutting business is making waves in the automotive industry with its latest spectacular creation.

Lasercut Works in Raymond Road was commissioned by Japanese car giant Toyota to make an exact scale working replica of a Lexus IS saloon – in cardboard.

The car, which has been used in the latest Lexus marketing campaign, has become a viral hit all over the internet, and director of Lasercut Works Daniel Ryan said it is the result of a lot of hard work from the team.

“It took around three months from start to finish,” he said. “It took us a full month at the beginning just to get the designs put together.”

After being sent component designs from Lexus and having the frame made by a modelling company, Lasercut then set about cutting more than two tonnes of cardboard into the relevant pieces of the car.

“The whole thing isn’t made completely out of cardboard,” he said. “We had to also have a metal chassis made which also took time in itself, and a real engine, so the car can be driven.”

From the two tonnes of cardboard, only 350kg ended up being used, with the rest being recycled.

“We were really happy with it,” he added. “It far exceeded my expectations of how it would look. The texture on the seats for example, it has a fabric look and looks amazing.”

The company usually creates specialist items for large companies or private collectors, but Daniel admits this could spell an exciting future for the company.

He said: “We have already had conversations from companies about producing small cars with us.

“We have ongoing work with other clients, but with all the publicity we are getting from the Lexus, this could be the start of a new division within the company – we are all excited about it.”

Lasercut Words were helped by Scales & Models with the construction and design of the car, while NVDK with the CAD assisted with the 3D computer modeling work.